Protective Air Barrier Sealant for Conditioned and Unconditioned Building Walls

ABSTRACT

A protective air barrier air barrier sealant and methods of applying the same, including a high density polyurethane chemistry provided in an amount, volume, and density effective for providing a protective air barrier for an enclosure, wherein the polyurethane material is combined with at least one UV, fire and antimicrobial protectant for providing UV protection to UV-exposed surfaces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/741,746, filed Jun. 17, 2015, which is acontinuation-in-part of U.S. patent application Ser. No. 12/785,900,filed May 24, 2010, which is a continuation-in-part of U.S. patentapplication Ser. No. 12/569,937, filed Sep. 30, 2009, each of which areexpressly incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to air barrier products. Furthermore, thepresent invention relates to air barrier products with ultraviolet,insulation, fire and antimicrobial protection for application tobuilding enclosures, walls, ductwork, and to systems and methodsrelating thereto.

2. Description of the Prior Art

It is generally known in the art to provide for air barrier systems tobuildings to control the unintended movement of air into and out ofbuilding enclosures. Air barrier systems essentially wrap the buildingshell and protect the building from the effects of air leakage. Airleakage can have detrimental effects on how a building functions andreduces the life span of a building.

Buildings are air-conditioned for comfort at considerable expense. Whenthis conditioned air leaks out of a building and unconditioned air leaksinto a building additional energy must then be used to condition thisair. Air leakage can result in an increased use of up to 30-40% inheating costs and 10-15% in cooling costs.

Buildings which have properly installed air barrier systems can operateproperly with a smaller HVAC system that does not have to compensate fora leaky building. In some cases, the reduction in mechanical equipmentsize and cost can offset the cost of the air barrier system.

Air barrier systems also provide a barrier to pollutants entering eitherthe building or the building enclosure. Water vapor, suspendedparticulates, dust, insects, smells, etc are all pollutants whichbuilding occupants prefer to keep out of the building. Water vapor thatleaks into the building enclosure can condense and form liquid water, akey component to corrosion and the development of mold.

Relevant prior art references include U.S. Pat. Nos. 4,318,959;4,596,725; 4,795,760; 4,939,184; 5,549,869; 5,583,230; 5,804,641;5,900,195; 6,402,201; 6,887,966; 7,459,167; and US Patent ApplicationPublication Nos. 20040077747; 20030207122.

Polyurethane foam is known in the prior art as an air barrier material.Like a number of plastics, polyurethane foam loses resistance whenexposed to UV light over a long period of time. With even short-termexposure, the surface of the foam changes, specifically the topmolecular layer is damaged. The surface then becomes brown and brittleto a depth of one or two mm. For this reason, a layer of UV protection,most often UV paint, is applied to polyurethane foam on exteriors. Ifthe polyurethane foam is applied to a roof it is necessary to use ahigh-quality UV protection layer with a long life. In some cases, thesepaints can also assume other functions such as water insulation orscratch protection. UV protection layers that are not integrated withthe polyurethane require maintenance because the layer becomes damagedand/or weathered.

SUMMARY OF THE INVENTION

The present invention relates to air barriers for building envelopes inboth conditioned and unconditioned living areas with ultraviolet,insulation, fire and antimicrobial protection.

It is an object of this invention to provide an air barrier sealantusing polyurethane chemistry and an integrated ultraviolet protectionelement provided in an amount, volume, and density effective forproviding a protective air barrier with UV-resistance for enclosureswith UV-exposed surfaces. The invention also provides insulation(R-value) to the wall along with ingredients that will make the sealantfire proof.

It is a further object of this invention to provide a protective airbarrier sealant to protect enclosures from microbes, mold, mildew,allergens, pollutants, gas deterioration, moisture deterioration, andinsect infestation through the use of antimicrobial technologies whichare incorporated into the material.

Yet another object of this invention is to provide methods for applyingto surfaces the product that provides air barrier protection, UVprotection and insulation (R-Value) and fire proofing.

These and other aspects of the present invention will become apparent tothose skilled in the art after a reading of the following description ofthe preferred embodiment when considered with the drawings, as theysupport the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph showing data associated with test results of the airbarrier sealant product according to one embodiment of the presentinvention.

DETAILED DESCRIPTION

Referring now to the drawings in general, the illustrations are for thepurpose of describing a preferred embodiment of the invention and arenot intended to limit the invention thereto.

The present invention provides a protective air barrier sealantincluding a high density polyurethane foam material provided in anamount, volume, and density effective for providing a protective airbarrier for an enclosure, wherein the air barrier material is combinedwith at least one UV, fire and antimicrobial protectant agent just priorto or at the time of application of the air barrier product to anenclosure surface. The air barrier sealant also provides a protectiveair barrier for surfaces from microbes, mold, mildew, gas deterioration,moisture deterioration, insects and damage from corrosion andcombinations thereof, and insulating (R-Value) properties for theenclosure. Furthermore, the present invention provides methods forapplying to surfaces the protective air barrier product that providesair barrier protection and insulative (R-Value) properties.

It is a further object of this invention to provide a protective airbarrier sealant to protect enclosures from microbes, mold, mildew,allergens, pollutants, gas deterioration, moisture deterioration, insectinfestation through the use of its antimicrobial technology which isincorporated into the sealant. Thus, an embodiment of the presentinvention includes at least one antimicrobial ingredient added to thisair barrier sealant.

None of the prior art references provide for an air barrier sealantwhich includes an integrated UV-protection agent wherein the barrier hasat least one exposed surface.

Thus there remains a need for an air barrier sealant for controlling theunintended movement of air into and out of a building enclosure andoffering integrated UV protection to exposed surfaces.

The protective air barrier, insulative, UV-protectant, fire proof andantimicrobial sealant of the present invention is importantlyestablished with an exposed polyurethane foam containing an integratedUV protectant on a UV-exposed surface area of an enclosure, and methodsof applying the same to hard surfaces for providing an air barriereffective against damage from moisture, air and vapor, and deteriorationby ultraviolet light, microorganisms, fungi, pests, and insects, as wellas providing a physical air barrier to resist damage and/or wear andstop air leakage into or out of the building enclosure.

The present invention provides an air barrier sealant for protectingsurfaces including a material having a top exposed surface that isspaced apart from a bottom surface wherein the spaced apart distanceprovides for an insulative thickness of the foam material, forming acoating on at least one enclosure surface. The product further includesat least one ultraviolet protectant capable of preventing ultravioletdegradation of the product. Preferably, the air barrier sealant is adual component formulation, wherein the air barrier components arecombined or mixed prior to or at the time of application of the airbarrier to the enclosure surface. In another embodiment, the air barriersealant is a single component formulation.

The ultraviolet protectant is added to the polyurethane chemistry at thetime of its manufacturing and is a raw ingredient of the finishedformula. It is designed to stay in suspension in the liquid until it issprayed at the job site. The ingredient is of a design and formulationthat it allows it to stay in suspension until sprayed, thus giving auniform ultraviolet protection throughout the finished product.

The UV protectant is selected from the group consisting of applicationsthat allow the applicator to spray one application which will providethe UV protection without having to take the time and money to spray asecond application. This one step application also provides for a veryfast project which allows for the applicator to do the work in a timelymanner and not hold up additional projects which may be scheduled forwork after the air barrier sealant is applied.

Furthermore, preferably, a colorant is used as our UV protectant in theair barrier sealant according to the present invention. In a preferredembodiment, the UV protectant colorizes the air barrier product blackand it is the black color that will absorb the UV rays which come incontact with the sealant. For example, carbon black can be used tocolorize black and provide UV protection. If the UV rays are absorbed bythe sealant material, then the material will not break down, whichextends the sealant protection for many years.

The insulation (R-Value) ability of the air barrier sealant according tothe present invention comes from the fact that this polyurethanechemistry utilizes closed cell technology at the time of itsmanufacturing and is a raw ingredient of the finished formula.Advantageously, the closed cell polyurethane foam of the presentinvention is the most energy efficient system available and becomes sowith increased density. This air barrier sealant uses the closed cellsof the chemistry to provide the insulation factor of the material whenit is applied and it is the ability of this sealant to “rise” that givesthe additional insulation factor. It is the two component chemistry assprayed through a proportioning type mixing system that allows for thefinished sealant to be manufactured upon coming in contact with air. Thefinished sealant is the combination of the two components mixing in theair and then curing on the wall surface. In one embodiment, at least oneof the components is put under a pressure of 1,500 psi. In anotherembodiment, at least one of the components is put under a temperature of130 to 150 degrees Fahrenheit.

The fire proof protectant used with the sealant according to the presentinvention is selected from the group consisting of special technologiesthat prevent the sealant from flashing or burning, such as, for example,polybrominated diphenyl ethers (PBDEs). The air barrier will add anadditional layer of protection to the building envelop because it willnot be considered a source for flame spread in the event of a fire.

The fire proofing ingredient is added to the polyurethane chemistry atthe time of its manufacturing and is a raw ingredient of the finishedformula. It is designed to stay in suspension in the liquid until it issprayed at the job site. The ingredient is of a design and formulationthat it allows it to stay in suspension until sprayed, thus giving auniform fireproof protection throughout the finished product.

The antimicrobial ingredient is added to the polyurethane chemistry atthe time of its manufacturing and is a raw ingredient of the finishedformula. It is designed to stay in suspension in the liquid until it issprayed at the job site. The ingredient is of a design and formulationthat it allows it to stay in suspension until sprayed, thus giving auniform antimicrobial protection throughout the finished product

The antimicrobial ingredient provides antifungal or antibacterialprotection or a combination thereof. Preferably, the combination of atleast one antimicrobial agent within the sealant material ensures thatno living organism grows on or within the sealant product including butnot limited to the prevention of mold, mildew, bacteria, fungi or othermicroorganisms. The barrier sealant provides protection to surfacesagainst external damage, agents or other forces including but notlimited to microbes, mold, mildew, gas deterioration, moisturedeterioration, insect damage and/or corrosion.

Various antimicrobial agents can be used. For example, quaternaryammonium compounds, such as Microban®, can be used. Additionally oralternatively, silver compounds can be used. More preferably, nanosilver, or silver nanoparticles, are used.

In methods of using the air barrier sealant according to the presentinvention, method steps include providing an air barrier productincluding a polyurethane material and at least one UV, fire andantimicrobial protectant agent; applying the air barrier product onto anenclosure surface in a continuous manner to form a continuous barrier;wherein upon application to the surface the polyurethane materialexpands to produce an insulative thickness between the enclosure surfaceand the top exposed surface of the air barrier sealant; and wherein thetop exposed surface of the air barrier product provides UV protection.The insulative thickness is preferably between about ⅛ inch to about 1inch. In another preferred embodiment the insulative thickness isbetween about ⅛ inch to about ¾ inches. In yet another preferredembodiment, the insulative thickness is between about ⅛ inch and ½ inch.In another preferred embodiment, the insulative thickness is betweenabout ⅛ inch and ¼ inch.

A dual component formulation, the combination of the at least one UV,fire and antimicrobial protectant agent with the polyurethane material,may be combined prior to application of the air barrier sealant to theenclosure surface, or at the time of application (through controlledmixing or combination with an application device that provides forspraying of the polyurethane material and the at least one UV, fire andantimicrobial protectant agent until the time of application).

Application of the air barrier sealant according to the presentinvention is preferably by spray application to the enclosure surface,and is a dual component mixing of the polyurethane material and the atleast one UV, fire and antimicrobial protectant on site or location ofthe enclosure to be coated and protected by the air barrier sealant. Inthis manner, the final formulation of the air barrier sealantcomposition occurs during the mixing process just prior to or uponapplication (in the air during spray application) to the enclosuresurface. At the time of application to the enclosure surface, thepolyurethane material expands to provide a thickness between about ⅛inch (3.175 mm) and about 1 inch (25.4 mm). The expansion of thepolyurethane material provides for insulative thickness to provideenergy efficient insulation when applied to building or room surfaces,including floors, walls, ceilings, etc. The expansion of thepolyurethane material also fills in cracks and holes that are majorsources of air intrusion. The final mixed and expanded state of the airbarrier product provides a top exposed surface that is resistant tocracking, breaking, chipping, corrosion, or other deterioration, andprovides a physical air barrier of protection to the coated enclosure.Also, this air barrier can act to reduce the impact upon the surface andincrease its resistance to damage. Furthermore, the air barrier sealantadheres to the enclosure surface, so it resists delaminating or peelingas well. The air barrier sealant is applicable to any enclosure surface,including but not limited to enclosure surfaces selected from metal,glass, wood, plastic, concrete, cinder block, asphalt, glass board,polyurethane foams and other air barrier type material such as caulksand the like, and combinations thereof.

In an exemplary embodiment, the air barrier sealant is applicable toductwork. The ductwork is preferably rectangular. In another embodiment,the ductwork is circular. The ductwork includes, by way of example andnot limitation, an air duct boot, a wall cap, and/or a roof cap.

Thus, the present invention eliminates uncontrolled air leakage,improves occupant comfort, health and safety, improves indoorenvironmental quality, improves structural strength, reducescondensation, moisture and mold problems, conforms to any shape, andprovides UV, fire and antimicrobial protection to exposed surfaces.

Referring now to testing results, in general, these test results areillustrations for the purpose of describing a preferred embodiment ofthe invention and are not intended to limit the invention thereto. Inthese test cases, laboratory application of the air barrier sealantaccording to the present invention was under ASTM standards applicablefor ASTM E2178-03 Standard Test Method for Air Permeance of BuildingMaterials, dated Aug. 21, 2009. This test was conducted at ¼″ thicknessand in accordance to the current ASTM standards for Air PermeanceProperties for building components. The evaluation was for one (1)specimen which was sealed within an air leakage test chamber.

Testing background and experimental protocols included the following:Specimens were sealed within the air leakage chamber. Air was exhaustedfrom the chamber at rates required to maintain test pressure differencesof 25, 50, 75, 100, 150, 250 and 300 Pa. The air leakage through thespecimens were measured at each successive pressure difference andmonitored for any physical changes. The air leakage of the specimens wasthen re-measured at pressure differentials of 100, 75, and 50 Pa, asrequired by the test procedure. Test results are indicated in Table 1for air permeance properties.

TABLE 1 Air Permeance Results in Accordance with ASTM E2178-03 AverageAverage Differential Calculated Air Calculated Air Pressure Flow Flow Pa(lbs/ft²) L/(s m²) CFM/ft² Thickness Note  25 (0.52) 0.000329 0.000076.8 mm SI units  50 (1.05) 0.000503 0.00010 are the  75 (1.57) 0.0006450.00013 primary units 100 (2.09) 0.000769 0.00015 of measure 150 (3.14)0.000986 0.00020 250 (5.23) 0.001348 0.00027 300 (6.27) 0.001508 0.00030100 (2.09) 0.000843 0.00017  75 (1.57) 0.000671 0.00013  50 (1.05)0.000487 0.00010

Conclusions from the testing include that the air barrier sealant met orexceeded the standard for air permeance for polyurethane foams andsealants as outlined by ABAA which is the Air Barrier Association ofAmerica, Inc.

Also, FIG. 1 is a graph showing data associated with test results of anair barrier sealant product according to one embodiment of the presentinvention. Importantly, the regression curve fitted to the results hasan R² value of 0.98689, indicating the non-deformable nature of the airbarrier product with regard to changes in pressure.

Due to the success of this test and some other preliminary tests, thesealant of the present invention is indicated to be in conformance withthe ABAA Spray Polyurethane Foam guidelines and to adhere to the teststandards as established by the ABAA Process for Approval of Air BarrierMaterials, Components and Assemblies JUNE 2007 Version 2.0 Draft(ABAA-10001-02). These test standards are shown in the following table,as applied to ¼″ thickness.

Product Test Requirements Property Standard Test Standard Title Unit MinMax Air ASTM Standard Test Method for Air L/(s · m²) — 0.02 - PermeanceE2178 Permeance of Building tested in Materials both directions FlameSpread ASTM Standard Test Method for — — 50 Characteristics E84-05Surface Burning Characteristics of Building Materials Water Vapor ASTMStandard Test Methods for ng/(Pa · s · m²) Declaration — TransmissionE-96- Water Vapor Transition of of 00e1 Materials - Water Methodthickness at which material meets 1 perm Thermal ASTM Standard TestMethod for m² · ° C./W 2.0 — Transmission E-177- Steady-State Heat Flux04 Measurements and Thermal Transmission Properties by Means of theGuarded-Hot- Plate Apparatus Compressive ASTM Standard test method forkPa 170 — Strength D-1621- Compressive Properties of 04a Rigid CellularPlastics Density ASTM Standard Test Method for kg/m³ 28 — D-1622-Apparent Density of Rigid 03 Cellular Plastics Tensile ASTM StandardTest Method for kPa 200 — Strength D-1623- tensile and Tensile Adhesive03 Properties of Rigid Cellular Plastics Dimensional ASTM Standard TestMethod for % — −1 Stability D-2126- response of Rigid Cellular — +8 04Plastics — +14  to Thermal and humid Aging −20° C. 80° C. 70° C., 97% ±3% R.H. Water ASTM Standard test method for % —  4 Absorption D-2842-Water Absorption of Rigid 01 Cellular Plastics Open Cell ASTM Standardtest Method for % —  8 Content D-2856- Open-Cell Content of Rigid 94Cellular Plastics by the Air Pycnometer Pull Adhesion ASTM Standard TestMethod for kPa 110 or — D-4541- Pull-Off Strength of Coatings report 02Using force at Portable Adhesion testers cohesion failure

The test results shown above in tables 1 and 2 were performed on a ¼″barrier. Because thicker barriers would provide at least theseproperties, the present invention provides for sealants with a range ofbetween about ¼″ and about 1″ with at least the same properties.Preferably, the barriers include a range of between about ¼″ to about3/16″ between about ¼″ to about ⅜″, between about ¼″ to about ½″,between about ¼″ to about ⅔″between about ¼″ to about ⅝″, between about¼″ to about ¾″, and between about ¼″ to about ⅞″.

Additionally, in one embodiment of the invention, the barrier has astrength of 367.80 psi. In another embodiment of the invention, thebarrier has an adhesion of 367.80 psi. In yet another embodiment, thestrength of the barrier is equal to the strength of the underlyingsubstrate. For example, if the barrier is applied to concrete, thestrength of the barrier is equal to the strength of the concrete.

Certain modifications and improvements will occur to those skilled inthe art upon a reading of the foregoing description. The above-mentionedexamples are provided to serve the purpose of clarifying the aspects ofthe invention and it will be apparent to one skilled in the art thatthey do not serve to limit the scope of the invention. All modificationsand improvements have been deleted herein for the sake of concisenessand readability but are properly within the scope of the presentinvention.

What is claimed is:
 1. An air barrier sealant comprising: a polyurethanematerial; wherein the air barrier sealant has a top exposed surface thatis spaced apart from a bottom surface by a thickness; wherein the bottomsurface substantially covers a surface of an object by the bottomsurface adhering to the object surface; wherein the air barrier sealanthas a tensile strength of not less than about 200 kPa.
 2. The airbarrier sealant of claim 1, wherein the polyurethane material is aclosed cell polyurethane material.
 3. The air barrier sealant of claim1, further comprising a second material with a colorant.
 4. The airbarrier sealant of claim 1, wherein the object is a piece of ductwork,the piece of ductwork comprising an air duct boot, a wall cap, and/or aroof cap.
 5. The air barrier sealant of claim 4, wherein the piece ofductwork is substantially rectangular.
 6. The air barrier sealant ofclaim 4, wherein the piece of ductwork is substantially circular.
 7. Theair barrier sealant of claim 1, wherein the air barrier sealant is adual component formulation.
 8. An air barrier sealant comprising: apolyurethane material; wherein the air barrier sealant has a top exposedsurface that is spaced apart from a bottom surface by a thickness;wherein the bottom surface substantially covers a surface of a substrateby the bottom surface adhering to the substrate; wherein the air barrierhas a tensile strength equal to a tensile strength of the substrate. 9.The air barrier sealant of claim 8, wherein the air barrier sealant hasa pull adhesion of not less than about 110 kPa.
 10. The air barriersealant of claim 8, wherein the polyurethane material is a closed cellpolyurethane material having no more than 8% open cells.
 11. The airbarrier sealant of claim 8, wherein the second material includes acolorant.
 12. The air barrier sealant of claim 8, wherein the airbarrier sealant is a dual component formulation.
 13. A method forproviding an air barrier sealant comprising: providing a polyurethanematerial in a first container; providing a material with suspended UV,fire and/or antimicrobial protectants in a second container; mixing anamount of the polyurethane material from the first container and anamount of the material with suspended UV, fire, and/or antimicrobialprotectants from the second container to create a mixture; applying themixture to a substrate surface; the mixture expanding from the substratesurface to produce a substantially uniform thickness; thereby creatingan air barrier on the substrate surface.
 14. The method of claim 13,wherein the polyurethane material in the first container is under apressure of about 1500 psi.
 15. The method of claim 13, wherein thepolyurethane material in the first container is maintained at atemperature between about 130 degrees Fahrenheit to about 150 degreesFahrenheit.
 16. The method of claim 13, wherein the substantiallyuniform thickness is not more than about 1 inch.
 17. The method of claim13, wherein mixing the amount of the polyurethane material from thefirst container and the amount of the material with suspended UV, fire,and/or antimicrobial protectants from the second container to create themixture is performed in air by spraying the amount of the polyurethanematerial from the first container and spraying the amount of thematerial with suspended UV, fire, and/or antimicrobial protectants fromthe second container, wherein the amount of the polyurethane materialand the amount of the material with suspended UV, fire, and/orantimicrobial protectants mix in the air.
 18. The method of claim 13,wherein a tensile strength of the air barrier on the substrate surfaceis not less than about 200 kPa.
 19. The method of claim 13, wherein atensile strength of the air barrier on the substrate surface is at leastequivalent to a tensile strength of the substrate.
 20. The method ofclaim 13, wherein the material with suspended UV, fire and/orantimicrobial protectants includes a colorant.